Method of manufacturing brushes



Nov. 28, 1944. F. NEUSCHAEQFER 2,363,685

METHOD OF MANUFACTURING BRUSHES Original Filed Feb. 19, 1942 g sheets shet 1 W* /%////%///%////////%//////////////MW INVENTOR.

ATTORNHS 1944 F. NEUSC'HAEFER 85 METHOD OF MANUFACTURING BRUSHES Original Filed Feb. 19, 1942 2 Sheets-Sheet 2 INVENTOR ATTORNEYS Patented Nov. 28, 1944 UNITED STATES} PATEN 1' OFFICE METHOD or MANUFAcrUniNG nnu'snns Franz Neuschaefer, Rye,'N. .Helen Neuschaefer, executrix of Franz Neuschaefer, deceased, assignor to Helen Neuschaei'er, Rye, N. Y. V

Original application February 19, 1942, Serial No.

431,473. Divided and this application October 26, 1942, Serial N0. 463,342 I 6 Claims.

' This invention relates to brushes, and methods for manufacturing same.

Thisapplication comprises a division of my copending application Ser. No. 431,473, filed.

February 19, 1942.

Various types of liquid, such as for cosmetic purposes, paints, adhesives, oils, etc,, are marketed in small bottles provided with caps or stoppers in which a small brush is mounted to suspend into the bottle, for applying the liquid to surfaces upon-which it is to be used. Such brushes heretofore have generally comprised a tuft of hair or other bristle material embraced by a stem portion in the form of a so-called. Japanese quill. or in the case of such brushes of domestic manufacture, '-a stem comprising a 4 single piece of sheet metal rolled or curled into a tubular shape. The present invention provides methods and means for economically manufacturing in large quantities, brushes for like purposes, as well as larger forms and other types of brushes, without using such quills and prefermetal for the ably without requiring the use of stems.

With preferred examples of the present invention, the stems for alarge plurality of the. brushes may be simultaneously formed with the brush tufts secured therein, by making use of strips' or layers of cardboard or the like materials such as heavy paper. plastic material, thin wood or other sheet material, which may be die-stamped in connection with properly arranged groups of the tufts, so as to simultaneously form comparatively large groups of separate or easily separable brushes with the stems aflixed thereon. Various further and'more specific objects, fea

layers restingthereon after being formed with corrugations and .with a plurality of brush tufts placed in such corrugations respectively;

Fig. 4 shows the die members, layers and tufts in position for pressing the brush parts together and for separating the material of eachbrush stem from the materialof adjacent stemsi Fig. 5 is a plan view showing the lower die member with a plurality of finished brushes rest-j ing thereon;

.Fig. 6 is a detailed sectional view illustrating an altemativemethod of practicing the invenf tion; a a

Fig. 7 is a perspective view illustrating two groups of the finished brushes in separate or separable condition; a I

- Figs. 8 and 9 are transverse-and longitudinal sectional views showing mold assemblies similar tofthat of- Fig. 4, but with-provision for heating the molds; lhis may bedesirable for drying or hardening an adhesive for securing the :layers "of stem material to the tufts, or for suitably processing the layers or strips of stem-forming material when some comprise a thermo-plastic substance; and

- Fig. 10 is a view similar to Fig. 5, but showing v an alternative embodiment of the invention. Referring now' to Figs. 1-5 in further detail, .a first or lower die member is-indicated at In,

a second or layer pre-forming die member at I 'I-,'

. and a third die member at l2.v The die members may be provided orformed with suitable pinsas atv l3 and apertures as at, for securing proper alignment in a conventional way.-

tures and advantages of the-invention will appear. from the detailed description given below taken in'connection with the accompanying drawings forming a part of this specification and embodiments of the invention. The invention consists in such novel features, arrangements, combinations of parts and method steps as are described in connection with the embodiments of the invention herein disclosed by way of ex;-v

ample only.

In the drawings, Figs. 1 and2 are side elevational views of die members in open and closed positions respective y. as arranged for shaping the strips or layers of stem-forming material with corrugations preparatory for application thereto of the brush tufts;

Fig. 3 is a view showing the lowermost of the die members of Figs. 1 and 2, with one of said illustrating by way of example various preferred The lower. die member may lie-formed with two elongated somewhat raised areas as at l5, l6 which are spaced apart by a'substantial distance such as indicated at. a (Fig. 5) for a purpose hereinafter explained. Each of these raised areas may be formed with transversely extending parallel or substantially parallel corrugations or scallops II, the corrugations at one area as shown being preferably in alignment with corresponding' corrugations on the other raised area. And

complementary to those" onfthe die member ID.

The second die member ll may be formed on .55 itslower and upper surfaces with a series of ridges as at l8, l8, adapted to substantially fit within the corrugations l1, l1 respectively. As

above indicated, the stem-forming material may comprise strips or layers of cardboard, heavy paper, thin wood, plastic or other sheet material. In carrying out the preferred embodiment of the method, a layer or strip of such material as at 20 is placed upon each of the corrugated areas l and I6 of the die member lb. The die member II is then placed in position on these strips and a similar pair of strips as at 2| ma be interposed between the upper surface of die member II and the lower raised corrugated surface areas of die member l2, as shown in Fig. 1. The die members may then be pressed together as in Fig. 2 whereby the layers 20, 2| are shaped with corrugations as shown. The pressure applied at this stage is preferably insuificient to cause the ridges or raised, areas as at 22 between corrugations to cut or sever the strips 2|], 2|. That is, the primary object of the operation illustrated in Fig. 2 is to simply form depressions or corrugations in the layers 20, 2| so that brush tufts as at 23 may be readily positioned in proper par-' two upper die members may be removed and the brush tufts 23 respectively may be placed in position in the corrugations of strip 20 as shown in Fig. 3. The tufts used are preferably long enough to be ultimately cut into lengths for providing at least two brushes. One end of each such tuft may be placed in position to rest withi in a corrugation on a strip 20, which in turn rests on raised area l5 of one side of the die member ill, and the other end of the tuft may be placed in a corrugation of another strip 25 resting on the other raised corrugated area I6 at the other side of the die member, as will be apparent from Fig. 5.

In case the layers 20, 2| are formed of fibrous or other sheet material which is not in itself of an adhesive character, then the ends of the brush tufts before being positioned as in Fig. 3 may be dipped in a suitable adhesive, or adhesive may be applied to the surfaces of the strips 20, 2| which are to contact the tufts. If desired, the layers 20, 2| may be impregnated as well as coatthe character of the material used for the strip and 2|, it may be desirable to merely sear the material along lines between the brush stems. so that eachindividual brush later my be easily broken or cut away manually or automatically. That is, in some cases it may be desired to provide automatic machinery for assembling the finished brushes in connection with bottle caps In that case, the brushes as'they form of two attached groups, whereby theindividual brushes ma be severed from the remainder of the group in the automatic assembling machine. o

Either before or after the brushes have been removed from the dies, the tufts may be severed ed with a suitable adhesive or thermo plastie material.

ditional adhesive means may be unnecessary.

After the tufts are in position as in Fig. 3, the upper layers or strips 2| may be placed thereon and the upper die member l2 then placed and pressed in position as shown in g. 4, sufll cient pressure being applied to squeeze the ends In the event the layers 20, 2| are formed of plastic or thermo-plastic material, ad-

of the brush tufts into compact condition and wholly sever the strips 20, 2| along lines between each brush tuft to thereby separate the material into distinct stem portions of the desired shape. However, in some cases, dependi g pon alonglines such as at 24 (Fig. 5) for example mid-way'between the two corrugated raised areas l5 and I6, viz. mid-way between the stem portions which have been formed on the respective ends of each tuft. Thus each tuft serves to provide active brush-forming portions as at 23, 23' for two separate brushes. The length of these active portions of the brushes may of course be.

determined and varied as desired by varying the spacing a (Fig. 5) between the two raised corrustrips may-be fitted into the die members l0, l2

as in Fig. 4, so that die member II and the operations of Figs. 1 and 2, will be unnecessary. In other cases it may be found possible to readily place or distribute the tufts, hair or bristles upon the lower strip 20 while it is still in flat condition and then place a flat strip 2| upon such bristles so placed, and to then apply the die member l2 as in Fig. 4. Such procedure will be further described hereinafter in connection with Fig. 6.

In other cases it maybe found desirable to use stem-forming material in the form of a powdered or paste plastic. In that event strips or bands of such plastic may be positioned above and below the tufts in substantially the same way as indicated at 20, 2| (Figs. 3 and 4) That is, as more specifically shown in Fig. 8, plastic or plaster material as at 25 may be distributed over-the corrugated surfaces of a. lower mold member Ill, the brush tufts 23 then being placed in position, whereupon the upper surfaces of the tufts are also then covered with plastic or plaster material 25 at the areas which will contact the upper mold member l2. As indicated, the mold members |0', |2' may be heated in a suitable well-known way to afford the desired treatment of the plastic material. under heat and pressure. A cross-sectional view taken lengthwise of the brushes, of a similar mold is indicated at Fig. 9. In some cases it may be desirable to provide the material 25 in the form of solid strips of relatively soft and deformable plastic which will harden upon application of the heat and pressure.

Fig. '7 illustrates two groups of the finished brushes as made with the dies or molds of Figs. 1-5. It will be noted that each brush comprises a tuft 2'3 and a stem comprising two semi-cylindrical portions 26, 21 of cardboard or the like. adhesively secured. together along their longitudinal edges anden'ibracing the end of the tuft.

and thus adhesively and substantially integrally secured thereto. Although these semi-cylina,ses,eac drical portions'as made according to the method of this invention may, if desired, be formed of thin. sneet metal adhesively secured in place,-

ordinarily a less expensive construction will be provided if cardboard or other inexpensive fibrous or plastic sheet material is used.

For some purposes the brushes need not necessarily comprise tufts of cylindrical shapes and it will be understood that the corrugations on the dies may be formed with various cross-sectional shapes depending upon the cross-sectional shape of the desired brush tuft or its stem. For example, in man cases the tufts may be substantiall fiat in cross section and in this event the invention may be practised in a manner indicated .in Fig. 6 without, arranging the bristles in separate tufts. Instead, the bristles of hair or other material may be combed straight andinterposed as a layer 30 between a pair of .layers or strips 3|, 32 of the desired stem-forming ma- What is claimed as new and desired to be secured'by Letters Patent is: 1. Method for forming simultaneously a plurality of brushes, which comprises arranging a series of tufts in generally parallel relationship,

. applying and adhesively securing thereto, two

ing along and substantially embracing a tuft, and

strips of deformable material extending transversely of the tuftsand spacedapart by a substantial distance, also deforming said strips into a plurality of distinct stem portions each extendsevering said tufts at points between said strips,

terial, including adhesive or to which adhesive has been applied. Then this assembly of material may be subjected to pressure with heat if desired,'between lower and upper die members ,as at 33,, 34. ,These die members will -'act in generally the same manner as with above described embodiment of Fig. 4 and will serve to separate notionly the stem-forming material to extent desired into distinct stems, but also serve toseparate the layer of bristles into separate tufts within each stem as formed.

In some cases, particularly where the bristles or tufts may be formed of long strands of artificial fiber,- it maybe desirable for quantity production to provide tufts of a length sufllcient so that they may be cut into more than two separate brushes. In thatevent, the hits may be of a length such as indicated in Fig. 10' so as to extend and protrude out beyond both edges of each of the corrugated raised die'areas l5,

16. In this case each completed brush stem.

portion as formed may be cut into two, as along 'lines 35, 36, as well as cutting thetufts along other natural or artificial fibers which may be used for brushes. The term strip or layer as used in the appended claims is intended to ap ply, except where otherwise specified, to material which may be solid, semi solid, or in paste or powdered form. While theinvention has been described-in detail with respect to particular preferred ex,-

amples, it will be understood by those skilled in the art after understanding the invention, that various changes and further modifications may be made without departing from the spiritand scope of the invention, and it is intended therefore in the appended; claims to'coverall such changes and modifications.-

thereby forming two groups of brushes.

2. Method for forming simultaneously a pinrality of brushes, which comprises interposing and adhesively securing a series of tufts in generally parallel arrangement between pairs of superposed strips of cardboard or the like, extending transversely of the tufts, with one pair spaced substantially from another, also die-forming said strips of each pair-coniqintly into a plurality of distinct stem portions, each embracing a tuft, and

severing said tufts at points between said pairs of strips, therebyforming groups of brushes.

3. Method for forming simultaneously a plurality of brushes, which comprises arranging a series 'oftufts in generally parallel relationship,

- applying thereto a strip of thermo-plastic material extending generally transverse to the'tufts, and shaping said material under heat and pressure sufficient to deform .same into a plurality of substantiallydistinct stem portions andsums, cient to also cause the thermo-plastic material of said portions to adhesively embrace said tufts respectively.

' 4. Method for forming simultaneously a plurality of brushes, which comprises arranging a series of'bristles in generally parallel relation ship in contact with a transverselyextending strip'of thermo-plastic material, and shaping said material under heat and pressure sufficient to deform same into a plurality of substantially distinct stem portions, and sumcient to also cause i the thermo-plastic material of each of said por tions to adhesively embrace a tuft of the bristles.

5. Method for forming simultaneously a plurality of brushes, which comprises arranging a series of bristles in generally parallel relationship in contact with at least two substantially spaced- 'apart thermo-plastic strips which extend transversely of the bristles, shaping said strips under heat and pressure sufilcient to deform same into a plurality of distinct stems, and sufficient to also cause the thermo-plastic material of each'of said portions to adhesively embrace a tuft of bristles,

and severing the tufts at points between said strips, thereby forming groups of brushes. V

6. Method for simultaneously forming a plurality of brushes comprising, corrugating transversely a strip of deformable material, placing ends of brush tufts in said corrugations, and covering said ends with, and adheslvely securing thereto and to said first strip, another similarly corrugated strip, so applied under pressure as to at least partially separate the strips into brush stems, alonglines of the corrugations. 

